U.S. patent number 11,260,346 [Application Number 16/018,017] was granted by the patent office on 2022-03-01 for inerting system.
This patent grant is currently assigned to HAMILTON SUNDSTRAND CORPORATION. The grantee listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to Jonathan Rheaume.
United States Patent |
11,260,346 |
Rheaume |
March 1, 2022 |
Inerting system
Abstract
A system is disclosed for providing inerting gas to a protected
space. The system includes an electrochemical cell including a
cathode, an anode separated by a separator that includes an ion
transfer medium, and an electrical connection to a power source or
power sink. A cathode fluid flow path is in operative fluid
communication with a catalyst at the cathode between a cathode
fluid flow path inlet and a cathode fluid flow path outlet, and an
anode fluid flow path is in operative fluid communication with a
catalyst at the anode, and includes an anode fluid flow path
outlet. A cathode supply fluid flow path is disposed between the
protected space and the cathode fluid flow path inlet, and an
inerting gas flow path is in operative fluid communication with the
cathode flow path outlet and the protected space.
Inventors: |
Rheaume; Jonathan (West
Hartford, CT) |
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Assignee: |
HAMILTON SUNDSTRAND CORPORATION
(Charlotte, NC)
|
Family
ID: |
67070660 |
Appl.
No.: |
16/018,017 |
Filed: |
June 25, 2018 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20190388832 A1 |
Dec 26, 2019 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D
53/229 (20130101); B64D 37/32 (20130101); B64D
45/00 (20130101); B01D 53/268 (20130101); A62C
3/08 (20130101); B01D 53/265 (20130101); B01D
53/326 (20130101); A62C 99/0018 (20130101); B01D
2257/80 (20130101); B01D 2257/104 (20130101); B01D
2256/10 (20130101); Y02T 50/40 (20130101); B01D
2259/4575 (20130101); B64D 2045/009 (20130101) |
Current International
Class: |
B01D
53/32 (20060101); B64D 45/00 (20060101); B64D
37/32 (20060101); B01D 53/26 (20060101); B01D
53/22 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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3284676 |
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Feb 2018 |
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EP |
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2007054316 |
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May 2007 |
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WO |
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Other References
Jonathan Rheaume, "Selective Method of Operation of Ullage
Passivation System",U.S. Appl. No. 15/378,687, filed Dec. 14, 2016.
cited by applicant .
European Search Report Issued in European Application No.
19182358.2 dated Jan. 8, 2020; 8 Pages. cited by applicant.
|
Primary Examiner: McFall; Nicholas
Attorney, Agent or Firm: Cantor Colburn LLP
Claims
What is claimed is:
1. A system for providing inerting gas to a protected space,
comprising an electrochemical cell comprising a cathode and an
anode separated by a separator comprising an ion transfer medium; a
cathode fluid flow path in operative fluid communication with a
catalyst at the cathode between a cathode fluid flow path inlet and
a cathode fluid flow path outlet; a cathode supply fluid flow path
between the protected space and the cathode fluid flow path inlet;
an anode fluid flow path in operative fluid communication with a
catalyst at the anode, including an anode fluid flow path outlet;
an electrical connection to a power source or power sink; an
inerting gas flow path in operative fluid communication with the
cathode flow path outlet and the protected space; a gas treatment
module configured to remove fuel vapor, smoke, or a contaminant
from the cathode supply flow path, wherein the gas treatment module
includes a membrane separator comprising the cathode supply fluid
flow path on a first side of a membrane, and the inerting gas flow
path as a sweep gas on a second side of the membrane.
2. The system of claim 1, further comprising a water removal module
on the cathode supply fluid flow path, or the cathode fluid flow
path, or the inerting gas flow path.
3. The system of claim 2, wherein the water removal module is on
the inerting gas flow path.
4. The system of claim 2, wherein the water removal module includes
any one or combination of: a heat exchanger condenser, a gas-liquid
separator, a membrane dryer, a desiccant.
5. The system of claim 4, wherein the water removal module
comprises a heat exchanger condenser and a membrane dryer.
6. The system of claim 5, wherein the membrane dryer includes the
inerting gas flow path on a first side of a membrane, and a sweep
gas flow path comprising ram air exhaust from a heat absorption
side of the heat exchanger condenser.
7. The system of claim 1, wherein the ion transfer medium comprises
a proton exchange membrane, and the electrochemical cell is
configured to produce protons at the anode and transfer the protons
across the proton exchange membrane to the cathode.
8. The system of claim 1, wherein the ion transfer medium comprises
a solid oxide, and the electrochemical cell is configured to
produce oxygen anions at the cathode and transfer the oxygen anions
across the solid oxide ion transfer medium to the anode.
9. The system of claim 1, wherein the inerting gas flow path is
further in operative communication with a fire suppression
system.
10. The system of claim 1, wherein the protected space comprises a
fuel tank ullage space.
11. An aircraft comprising: an aircraft body and an engine; an
electrochemical cell comprising a cathode and an anode separated by
a separator comprising an ion transfer medium; a cathode fluid flow
path in operative fluid communication with a catalyst at the
cathode between a cathode fluid flow path inlet and a cathode fluid
flow path outlet; a cathode supply fluid flow path between the
protected space and the cathode fluid flow path inlet; an anode
fluid flow path in operative fluid communication with a catalyst at
the anode, including an anode fluid flow path outlet; an electrical
connection to a power source or power sink; an inerting gas flow
path in operative fluid communication with the cathode flow path
outlet and the protected space; a gas treatment module configured
to remove fuel vapor, smoke, or a contaminant from the cathode
supply flow path, wherein the gas treatment module includes a
membrane separator comprising the cathode supply fluid flow path on
a first side of a membrane, and the inerting gas flow path as a
sweep gas on a second side of the membrane.
12. The aircraft of claim 11, wherein the protected space is
selected from a fuel tank ullage space, a cargo hold, or an
equipment bay.
13. The aircraft of claim 12, wherein the cathode supply fluid flow
path receives fluid flow from any one or more of the fuel tank
ullage space, cargo hold, or equipment bay, and the inerting gas
flow path delivers inerting gas to any one or more of the fuel tank
ullage space, cargo hold, or equipment bay.
14. The aircraft of claim 11, wherein the protected space comprises
a fuel tank ullage space.
15. A method of inerting a protected space, comprising delivering
gas from the protected space to a cathode of an electrochemical
cell; reducing oxygen at the cathode to generate oxygen-depleted
air at the cathode of the electrochemical cell; directing the
oxygen-depleted air from the cathode of the electrochemical cell
along an inerting gas flow path to the protected space; directing
gas from a cathode supply flow path to a gas treatment module
configured to remove fuel vapor, smoke, or a contaminant from the
cathode supply flow path, wherein the gas treatment module includes
a membrane separator comprising the cathode supply fluid flow path
on a first side of a membrane, and the inerting gas flow path as a
sweep gas on a second side of the membrane.
Description
BACKGROUND
The subject matter disclosed herein generally relates to systems
for providing inerting gas, and more particularly to inerting
systems for aircraft fuel tanks.
It is recognized that fuel vapors within fuel tanks become
combustible or explosive in the presence of oxygen. An inerting
system decreases the probability of combustion or explosion of
flammable materials in a fuel tank by maintaining a chemically
non-reactive or inerting gas, such as nitrogen-enriched air, in the
fuel tank vapor space, also known as ullage. Three elements are
required to initiate combustion or an explosion: an ignition source
(e.g., heat), fuel, and oxygen. The oxidation of fuel may be
prevented by reducing any one of these three elements. If the
presence of an ignition source cannot be prevented within a fuel
tank, then the tank may be made inert by: 1) reducing the oxygen
concentration, 2) reducing the fuel concentration of the ullage to
below the lower explosive limit (LEL), or 3) increasing the fuel
concentration to above the upper explosive limit (UEL). Many
systems reduce the risk of oxidation of fuel by reducing the oxygen
concentration by introducing an inerting gas such as
nitrogen-enriched air (NEA) (i.e., oxygen-depleted air or ODA) to
the ullage, thereby displacing oxygen with a mixture of nitrogen
and oxygen at target thresholds for avoiding explosion or
combustion.
It is known in the art to equip aircraft with onboard inerting gas
generating systems, which supply nitrogen-enriched air to the vapor
space (i.e., ullage) within the fuel tank. The nitrogen-enriched
air has a substantially reduced oxygen content that reduces or
eliminates oxidizing conditions within the fuel tank. Onboard
inerting gas generating systems typically use membrane-based gas
separators. Such separators contain a membrane that is permeable to
oxygen and water molecules, but relatively impermeable to nitrogen
molecules. A pressure differential across the membrane causes
oxygen molecules from air on one side of the membrane to pass
through the membrane, which forms oxygen-enriched air (OEA) on the
low-pressure side of the membrane and NEA on the high-pressure side
of the membrane. The requirement for a pressure differential
necessitates a source of compressed or pressurized air. Bleed air
from an aircraft engine or from an onboard auxiliary power unit can
provide a source of compressed air; however, this can reduce
available engine power and also must compete with other onboard
demands for compressed air, such as the onboard air environmental
conditioning system and anti-ice systems. Moreover, certain flight
conditions such as during aircraft descent can lead to an increased
demand for NEA at precisely the time when engines could be
throttled back for fuel savings so that maintaining sufficient
compressed air pressure for meeting the pneumatic demands may come
at a significant fuel burn cost. Additionally, there is a trend to
reduce or eliminate bleed-air systems in aircraft; for example
Boeing's 787 has a no-bleed systems architecture, which utilizes
electrical systems to replace most of the pneumatic systems to
improve fuel efficiency, as well as reduce weight and lifecycle
costs. Other aircraft architectures may adopt low-pressure bleed
configurations where engine design parameters allow for a bleed
flow of compressed air, but at pressures less than the 45 psi air
(unless stated otherwise, "psi" as used herein means absolute
pressure in pounds per square inch, i.e., psia) that has been
typically provided in the past to conventional onboard
environmental control systems. A separate compressor or compressors
can be used to provide pressurized air to the membrane gas
separator, but this undesirably increases aircraft payload, and
also represents another onboard device with moving parts that is
subject to maintenance issues or device failure.
BRIEF DESCRIPTION
A system is disclosed for providing inerting gas to a protected
space. The system includes an electrochemical cell including a
cathode, an anode separated by a separator that includes an ion
transfer medium, and an electrical connection to a power source or
power sink. A cathode fluid flow path is in operative fluid
communication with a catalyst at the cathode between a cathode
fluid flow path inlet and a cathode fluid flow path outlet, and an
anode fluid flow path is in operative fluid communication with a
catalyst at the anode, and includes an anode fluid flow path
outlet. A cathode supply fluid flow path is disposed between the
protected space and the cathode fluid flow path inlet, and an
inerting gas flow path is in operative fluid communication with the
cathode flow path outlet and the protected space.
In some embodiments, the system further includes a gas treatment
module configured to remove fuel vapor, smoke, or a contaminant
from the cathode supply flow path.
In some embodiments, the gas treatment module includes any one or
combination of: a filter, an adsorbent, a membrane separator, a
catalytic combustor, electrostatic precipitator, a scrubber, a
condensing separator, and a gas-liquid separator.
In some embodiments, the gas treatment module includes a membrane
separator comprising the cathode supply fluid flow path on a first
side of a membrane, and the inerting gas flow path as a sweep gas
on a second side of the membrane.
In any one or combination of the foregoing embodiments, the system
can further include a water removal module on the cathode supply
fluid flow path, or the cathode fluid flow path, or the inerting
gas flow path.
In any one or combination of the foregoing embodiments, the water
removal module is on the inerting gas flow path.
In any one or combination of the foregoing embodiments, the water
removal module includes any one or combination of: a heat exchanger
condenser, a gas-liquid separator, a membrane dryer, a
desiccant.
In any one or combination of the foregoing embodiments, the water
removal module comprises a heat exchanger condenser and a membrane
dryer.
In some embodiments, the membrane dryer includes the inerting gas
flow path on a first side of a membrane, and a sweep gas flow path
comprising ram air exhaust from a heat absorption side of the heat
exchanger condenser.
In any one or combination of the foregoing embodiments, the ion
transfer medium comprises a proton exchange membrane, and the
electrochemical cell is configured to produce protons at the anode
and transfer the protons across the proton exchange membrane to the
cathode.
In any one or combination of the foregoing embodiments, the ion
transfer medium comprises a solid oxide, and the electrochemical
cell is configured to produce oxygen anions at the cathode and
transfer the oxygen anions across the solid oxide ion transfer
medium to the anode.
In any one or combination of the foregoing embodiments, the
inerting gas flow path is further in operative communication with a
fire suppression system.
In any one or combination of the foregoing embodiments, the
protected space comprises a fuel tank ullage space.
According to some embodiments, an aircraft comprises an aircraft
body and an engine, and the system of any one or combination of the
foregoing embodiments.
According to any one or combination of the foregoing embodiments,
the aircraft protected space is selected from a fuel tank ullage
space, a cargo hold, or an equipment bay.
According to any one or combination of the foregoing embodiments,
the aircraft cathode supply fluid flow path receives fluid flow
from any one or more of the fuel tank ullage space, cargo hold, or
equipment bay, and the inerting gas flow path delivers inerting gas
to any one or more of the fuel tank ullage space, cargo hold, or
equipment bay.
According to any one or combination of the foregoing embodiments,
the aircraft protected space comprises a fuel tank ullage
space.
According to some embodiments, a method is disclosed of inerting a
protected space. According to the method gas is delivered from the
protected space to a cathode of an electrochemical cell. Oxygen is
reduced at the cathode to generate oxygen-depleted air at the
cathode of the electrochemical cell, and the oxygen-depleted air is
directed from the cathode of the electrochemical cell along an
inerting gas flow path to the protected space.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any
way. With reference to the accompanying drawings in which like
elements are numbered alike:
FIG. 1A is a schematic illustration of an aircraft that can
incorporate various embodiments of the present disclosure;
FIG. 1B is a schematic illustration of a bay section of the
aircraft of FIG. 1A;
FIG. 2 is a schematic depiction an example embodiment of an
electrochemical cell;
FIG. 3 is a schematic illustration of an example embodiment of an
electrochemical inerting system;
FIG. 4 is a schematic illustration of an example embodiment of an
PEM electrochemical cell inerting system; and
FIG. 5 is a is a schematic illustration of an example embodiment of
a solid oxide electrochemical cell inerting system
DETAILED DESCRIPTION
A detailed description of one or more embodiments of the disclosed
apparatus and method are presented herein by way of exemplification
and not limitation with reference to the Figures
As shown in FIGS. 1A-1B, an aircraft includes an aircraft body 101,
which can include one or more bays 103 beneath a center wing box.
The bay 103 can contain and/or support one or more components of
the aircraft 101. For example, in some configurations, the aircraft
can include environmental control systems and/or fuel inerting
systems within the bay 103. As shown in FIG. 1B, the bay 103
includes bay doors 105 that enable installation and access to one
or more components (e.g., environmental control systems, fuel
inerting systems, etc.). During operation of environmental control
systems and/or fuel inerting systems of the aircraft, air that is
external to the aircraft can flow into one or more ram air inlets
107. The outside air may then be directed to various system
components (e.g., environmental conditioning system (ECS) heat
exchangers) within the aircraft. Some air may be exhausted through
one or more ram air exhaust outlets 109.
Also shown in FIG. 1A, the aircraft includes one or more engines
111. The engines 111 are typically mounted on the wings 112 of the
aircraft and are connected to fuel tanks (not shown) in the wings,
but may be located at other locations depending on the specific
aircraft configuration. In some aircraft configurations, air can be
bled from the engines 111 and supplied to environmental control
systems and/or fuel inerting systems, as will be appreciated by
those of skill in the art.
Referring now to FIG. 2, an electrochemical cell is schematically
depicted. The electrochemical cell 10 comprises a separator 12 that
includes an ion transfer medium. As shown in FIG. 2, the separator
12 has a cathode 14 disposed on one side and an anode 16 disposed
on the other side. Cathode 14 and anode 16 can be fabricated from
catalytic materials suitable for performing the needed
electrochemical reaction (e.g., the oxygen-reduction reaction at
the cathode and an oxidation reaction at the anode). Exemplary
catalytic materials include, but are not limited to, nickel,
platinum, palladium, rhodium, carbon, gold, tantalum, titanium,
tungsten, ruthenium, iridium, osmium, zirconium, alloys thereof,
and the like, as well as combinations of the foregoing materials.
Some organic materials and metal oxides can also be used as
catalysts, as contrasted to electrochemical cells utilizing proton
exchange membranes where the conditions preclude the use of metal
oxide catalysts. Examples of metal oxide catalysts include, but are
not limited to ruthenium oxides, iridium oxides or transition-metal
oxides, generically depicted as M.sub.xO.sub.y, where x and y are
positive numbers [capable of forming a stable catalytic metal oxide
such as Co.sub.3O.sub.4. Cathode 14 and anode 16, including
catalyst 14' and catalyst 16', are positioned adjacent to, and
preferably in contact with the separator 12 and can be porous metal
layers deposited (e.g., by vapor deposition) onto the separator 12,
or can have structures comprising discrete catalytic particles
adsorbed onto a porous substrate that is attached to the separator
12. Alternatively, the catalyst particles can be deposited on high
surface area powder materials (e.g., graphite or porous carbons or
metal-oxide particles) and then these supported catalysts may be
deposited directly onto the separator 12 or onto a porous substrate
that is attached to the separator 12. Adhesion of the catalytic
particles onto a substrate may be by any method including, but not
limited to, spraying, dipping, painting, imbibing, vapor
depositing, combinations of the foregoing methods, and the like.
Alternately, the catalytic particles may be deposited directly onto
opposing sides of the separator 12. In either case, the cathode and
anode layers 14 and 16 may also include a binder material, such as
a polymer, especially one that also acts as an ionic conductor such
as anion-conducting ionomers. In some embodiments, the cathode and
anode layers 14 and 16 can be cast from an "ink," which is a
suspension of supported (or unsupported) catalyst, binder (e.g.,
ionomer), and a solvent that can be in a solution (e.g., in water
or a mixture of alcohol(s) and water) using printing processes such
as screen printing or ink jet printing.
The cathode 14 and anode 16 can be controllably electrically
connected by electrical circuit 18 to a controllable electric power
system 20, which can include a power source (e.g., DC power
rectified from AC power produced by a generator powered by a gas
turbine engine used for propulsion or by an auxiliary power unit)
and optionally a power sink. In some embodiments, the electric
power system 20 can optionally include a connection to an electric
power sink (e.g., one or more electricity-consuming systems or
components onboard the vehicle) with appropriate switching, power
conditioning, or power bus(es) for such on-board
electricity-consuming systems or components, for optional operation
in an alternative fuel cell mode. Inerting gas systems with
electrochemical cells that can alternatively operate to produce
nitrogen-enriched air in a fuel-consuming power production (e.g.,
fuel cell) mode or a power consumption mode (e.g., electrolyzer
cell) are disclosed in US patent application publication no.
2017/0331131 A1, the disclosure of which is incorporated herein by
reference in its entirety.
With continued reference to FIG. 2, a cathode supply fluid flow
path 22 directs gas from a fuel tank ullage space (not shown) into
contact with the cathode 14. Oxygen is electrochemically depleted
from air along the cathode fluid flow path 23, and is discharged as
nitrogen-enriched air (NEA) (i.e., oxygen-depleted air, ODP) to an
inerting gas flow path 24 for delivery to an on-board fuel tank
(not shown), or to a vehicle fire suppression system associated
with an enclosed space (not shown), or controllably to either or
both of a vehicle fuel tank or an on-board fire suppression system.
An anode fluid flow path 25 is configured to controllably receive
an anode supply fluid from an anode supply fluid flow path 22'. The
anode fluid flow path 25 can include water if the electrochemical
cell is configured for proton transfer across the separator 12
(e.g., a proton exchange membrane (PEM) electrolyte or phosphoric
acid electrolyte). If the electrochemical cell is configured for
oxygen anion transfer across the separator 12 (e.g., a solid oxide
electrolyte), it can optionally be configured to receive air along
the anode fluid flow path 25. Although not stoichiometrically
required by the electrochemical reactions of the solid oxide
electrochemical cell, airflow to the anode during power-consumption
mode can have the technical effects of diluting the potentially
hazardous pure heated oxygen at the anode, and providing thermal
regulation to the cell. If the system is configured for alternative
operation in a fuel cell mode, the anode fluid flow path 25 can be
configured to controllably also receive fuel (e.g., hydrogen for a
proton-transfer cell, hydrogen or hydrocarbon reformate for a solid
oxide cell). Anode exhaust 26 can, depending on the type of cell
and the anode exhaust content, be exhausted or subjected to further
processing. Control of fluid flow along these flow paths can be
provided through conduits and valves (not shown), which can be
controlled by a controller 36.
In some embodiments, the electrochemical cell 10 can operate
utilizing the transfer of protons across the separator 12.
Exemplary materials from which the electrochemical proton transfer
electrolytes can be fabricated include proton-conducting ionomers
and ion-exchange resins. Ion-exchange resins useful as proton
conducting materials include hydrocarbon- and fluorocarbon-type
resins. Fluorocarbon-type resins typically exhibit excellent
resistance to oxidation by halogen, strong acids, and bases. One
family of fluorocarbon-type resins having sulfonic acid group
functionality is NAFION.TM. resins (commercially available from E.
I. du Pont de Nemours and Company, Wilmington, Del.).
Alternatively, instead of an ion-exchange membrane, the separator
12 can be comprised of a liquid electrolyte, such as sulfuric or
phosphoric acid, which may preferentially be absorbed in a
porous-solid matrix material such as a layer of silicon carbide or
a polymer than can absorb the liquid electrolyte, such as
poly(benzoxazole). These types of alternative "membrane
electrolytes" are well known and have been used in other
electrochemical cells, such as phosphoric-acid fuel cells.
During operation of a proton transfer electrochemical cell in the
electrolyzer mode, water at the anode undergoes an electrolysis
reaction according to the formula
H.sub.2O.fwdarw.1/2O.sub.2+2H.sup.++2e.sup.- (1) The electrons
produced by this reaction are drawn from electrical circuit 18
powered by electric power source 20 connecting the positively
charged anode 16 with the cathode 14. The hydrogen ions (i.e.,
protons) produced by this reaction migrate across the separator 12,
where they react at the cathode 14 with oxygen in the cathode flow
path 23 to produce water according to the formula
1/2O.sub.2+2H.sup.++2e.sup.-.fwdarw.H.sub.2O (2) Removal of oxygen
from cathode flow path 23 produces nitrogen-enriched air exiting
the region of the cathode 14. The oxygen evolved at the anode 16 by
the reaction of formula (1) is discharged as oxygen or an
oxygen-enriched air stream as anode exhaust 26.
During operation of a proton transfer electrochemical cell in a
fuel cell mode, fuel (e.g., hydrogen) at the anode undergoes an
electrochemical oxidation according to the formula
H.sub.2.fwdarw.2H.sup.++2e.sup.- (3) The electrons produced by this
reaction flow through electrical circuit 18 to provide electric
power to an electric power sink (not shown). The hydrogen ions
(i.e., protons) produced by this reaction migrate across the
separator 12, where they react at the cathode 14 with oxygen in the
cathode flow path 23 to produce water according to the formula (2).
1/2O.sub.2+2H.sup.++2e.sup.-.fwdarw.H.sub.2O (2) Removal of oxygen
from cathode flow path 23 produces nitrogen-enriched air exiting
the region of the cathode 14.
As mentioned above, the electrolysis reaction occurring at the
positively charged anode 16 requires water, and the ionic polymers
used for a PEM electrolyte perform more effectively in the presence
of water. Accordingly, in some embodiments, a PEM membrane
electrolyte is saturated with water or water vapor. Although the
reactions (1) and (2) are stoichiometrically balanced with respect
to water so that there is no net consumption of water, in practice
moisture will be removed by NEA 24 (either entrained or evaporated
into the nitrogen-enriched air) as it exits from the region of
cathode 14. Accordingly, in some exemplary embodiments, water is
circulated past the anode 16 along an anode fluid flow path (and
optionally also past the cathode 14). Such water circulation can
also provide cooling for the electrochemical cells. In some
exemplary embodiments, water can be provided at the anode from
humidity in air along an anode fluid flow path in fluid
communication with the anode. In other embodiments, the water
produced at cathode 14 can be captured and recycled to anode 16
(not shown). It should also be noted that, although the embodiments
are contemplated where a single electrochemical cell is employed,
in practice multiple electrochemical cells will be electrically
connected in series with fluid flow to the multiple cathode and
anode flow paths routed through manifold assemblies.
In some embodiments, the electrochemical cell 10 can operate
utilizing the transfer of oxygen anions across the separator 12.
Exemplary materials from which the electrochemical oxygen
anion-transporting electrolytes can be fabricated include solid
oxides such as yttria-stabilized zirconia and/or ceria doped with
rare earth metals. These types of materials are well known and have
been used in solid oxide fuel cells (SOFC).
During operation of an oxygen anion transfer electrochemical cell
in a power consuming (e.g., electrolyzer) mode, oxygen at the
cathode undergoes an electrochemical reduction reaction according
to the formula 1/2O.sub.2+2e.sup.-.fwdarw.O.sup.- (4) The electrons
consumed by this reaction are drawn from electrical circuit 18
powered by electric power source 20 connecting the positively
charged anode 16 with the cathode 14. The oxygen anions produced by
this reaction migrate across the separator 12, where they undergo
an electrochemical oxidation reaction at the anode 14 according to
the formula O.sup.-.fwdarw.1/2O.sub.2+2e.sup.- (5) Removal of
oxygen from cathode flow path 24 produces nitrogen-enriched air
exiting the region of the cathode 14. The oxygen produced at the
anode 16 by the reaction of formula (5) is discharged as oxygen or
an oxygen-enriched air stream as anode exhaust 26.
During operation of an oxygen ion transfer electrochemical cell in
a fuel cell mode, oxygen at the cathode undergoes an
electrochemical reduction reaction according to the formula
1/2O.sub.2+2e.fwdarw.O.sup.- (4) The electrons consumed by this
reaction are drawn from electrons liberated at the anode, which
flow through electrical circuit 18 to provide electric power to
electric power sink (not shown). The oxygen anions produced by this
reaction migrate across the separator 12, where they react with
fuel such as hydrogen at the anode according to the formula
H.sub.2+O.sup.-.fwdarw.H.sub.2O+2e.sup.- (6) Carbon monoxide (e.g.,
contained in fuel reformate) can also serve as fuel in solid oxide
electrochemical cells. In this case, the oxygen anions produced at
the cathode according to formula (4) migrate across the separator
12 where they react with carbon monoxide at the anode according to
the formula CO+O.sup.-.fwdarw.CO.sub.2+2e.sup.- (7) Removal of
oxygen from cathode flow path 24 produces nitrogen-enriched air
exiting the region of the cathode 14. The steam and carbon dioxide
produced at the anode 16 by the reactions of formulas (6) and (7)
respectively is discharged along with unreacted fuel as anode
exhaust 26. The unreacted fuel that exits anode 16 via anode
exhaust flow path 26 can be recycled to fuel flow path 32 using an
ejector or blower (not shown). It can also be fed to a fuel
processing unit wherein the steam and carbon dioxide contribute to
reforming.
In some embodiments, a controller 36 can be in operative
communication with the electrochemical cell, the membrane gas
separator, and any associated valves, pumps, compressors, conduits,
or other fluid flow components, and with switches, inverters,
regulators, sensors, and other electrical system components, and
any other system components to selectively operate the inerting gas
system. These control connections can be through wired electrical
signal connections (not shown) or through wireless connections. In
some embodiments, the controller 36 can be configured to operate
the system according to specified parameters, as discussed in
greater detail further below.
Turning now to FIG. 3, there is shown an inerting system 50 with an
electrochemical cell stack 52 that receives a cathode supply feed
22 from a protected space 54 such as an aircraft fuel tank ullage
space, a cargo hold, or an equipment bay, and is electrically
connected to a power source or sink (not shown). For illustration
purposes, the protected space 54 is shown as an ullage space in a
fuel tank 56 with vent 58, but the protected space could also be a
cargo hold or an equipment bay. Gas from the protected space 54 is
directed by a fan or blower 60 through an optional flame arrestor
62 and optional gas treatment module 64 to an internal cathode
inlet header (not shown) to cathode fluid flow paths 23 along the
cathodes in the cell stack. For ease of illustration, anode fluid
flow through an anode header of the stack 64 is not shown in FIGS.
3-4, but can be as according to FIG. 2 and the description thereof
with connection to process materials and equipment accordingly as
described (e.g., fuel or water feed connections to an anode side of
a PEM electrochemical cell for operation in fuel cell or
electrolyzer mode, respectively). Various types of gas treatment
modules can be utilized, either integrated into a single module or
as separate modules disposed in series or parallel along the
cathode supply fluid flow path 22. In some embodiments, the gas
treatment module can be configured to remove fuel vapor from the
cathode supply gas, or to remove one or more fuel contaminants from
the cathode supply gas, or to remove other contaminants such as
smoke such as from a fire in a cargo hold if the protected space
includes a cargo hold, or any combination of the above from the
cathode supply gas. Examples of gas treatments include membrane
separators (e.g., a reverse selective membrane with a membrane that
has greater solubility with fuel vapor than air) with an optional
sweep gas on the side of the membrane opposite the cathode supply
fluid flow path, adsorbents (e.g., activated carbon adsorbent as a
fuel vapor trap), or a combustor such as a catalytic oxidation
reactor or other combustion reactor. Examples of gas treatments
that can remove contaminants include any of the above-mentioned gas
treatments for removal of fuel vapor (e.g., adsorbents or catalysts
for removal or deactivation of fuel contaminants such as
sulfur-containing compounds that could poison catalysts in the
electrochemical cell, as well as other treatments such as filters
or activated carbon adsorbers.
With continued reference to FIG. 3, oxygen-depleted air is
discharged from the cathode side of the electrochemical cells in
the electrochemical cell stack 52 along the inerting gas flow path
24 toward the protected space(s) 54. In some embodiments, a water
removal module comprising one or more water removal stations can be
disposed between the electrochemical cell stack 52 and the
protected space(s) 54. Examples of water removal modules include
heat exchanger condensers (i.e., a heat exchanger in which removal
of heat condenses water vapor to liquid water, which is separated
from the gas stream), membrane separators, desiccants. In some
embodiments or operating conditions (e.g., on-ground operation),
the heat exchanger condenser 66 may not remove all of the desired
amount of water to be removed, so supplemental drying can
optionally be provided. As shown in FIG. 3, a heat exchanger
condenser 66 cooled by ram air 68 removes water from the inerting
gas, and an additional dryer 70 such as a membrane separator or
desiccant removes residual water not removed by the heat exchanger
condenser 66. Sensors such as humidity sensor 72, temperature
sensor 74, or oxygen sensor 76 can monitor the quality of the
inerting gas, and used to control when and under what parameters
the system should be operated. Additional optional features, such
as check valve 76 and flame arrestor 78, can help promote safe and
efficient flow of inerting gas to the protected space(s) 54.
Turning to FIG. 4, an example embodiment of an inerting system 50'
with a PEM electrochemical cell 52' is shown. This figure is
otherwise the same as FIG. 3 except as described below. As shown in
FIG. 4, a reverse selective membrane gas treatment module 64' and a
filter 64'' on the cathode supply fluid flow path includes a
membrane 65 in which fuel vapor has a greater solubility than air
(oxygen and nitrogen molecules). Membrane separators and their use
are described in greater detail in US patent application
Publication no. 2017/0368496 A1, the disclosure of which is
incorporated herein by reference in its entirety. The inerting gas
flow path 24 is routed along the opposite side of the membrane 65
from the cathode supply path. The preferential selectivity of the
membrane 65 for the fuel vapor promotes transfer of fuel vapor
molecules across the membrane 65 to the inerting gas flow path 24
acting as a sweep gas.
A water removal module in the form of a membrane separator 80 is
disposed on the inerting gas flow path. As shown in FIG. 4, the
membrane separator 80 includes a membrane 82 in which water has a
greater solubility than air (oxygen and nitrogen molecules) or fuel
vapor. Used ram air discharge 78 from the heat exchanger condenser
66 is routed along the opposite side of the membrane from the
inerting gas flow path. The preferential selectivity of the
membrane 82 for water promotes transfer of water molecules across
the membrane 82 to the ram air discharge 78 acting as a sweep gas.
The membrane 82, in different modes of operation, selectively
transports water vapor. Various materials and configurations can be
utilized for the gas separation membrane. Gas separation membranes
can rely on one or more physical phenomena for selectivity in
transportation of gases across the membrane. In some embodiments, a
selective membrane can rely on size-selective pathways through the
membrane that selectively allows transport of smaller molecules
over larger molecules. Examples of such membranes include membranes
that selectively allow faster transport of smaller water molecules
compared to larger nitrogen, oxygen, or fuel molecules. Such
membranes typically rely on molecule size-selective tortuous paths
through a non-porous polymer matrix in the form of a thin film
deposited onto a microporous layer. In addition to molecular size,
the condensability of a molecule is another parameter that can be
used in membrane-based gas separations: the more condensable
molecule is selectively permeated over the less condensable
molecule(s) due to its higher solubility in the polymer matrix,
which in turn leads to a larger driving force for permeation. Since
water molecules are both much smaller and more condensable than
oxygen and nitrogen, the selective permeation of water can be
accomplished with essentially any polymer-based membrane. Examples
of selective materials for water include polyimides known for use
in dehydration applications or
2,2-bistrifluoromethyl-4,5-difluoro-1,3-dioxole/tetrafluoroethylene,
silicone rubbers (polydimethyl siloxane, polyoctylmethyl siloxane),
polysulfones, polyethers (e.g., a copolymer of poly(ethylene oxide)
(PEO) and poly(butylene therephthalate) (PBT), polycarbonates,
poly(4-methyl-2-pentyne), poly-trimethyl-silyl-propyne (PTMSP),
etc. The gas selective membrane can include any of the above
materials, alone or in combination with each other or other
selective materials. Combinations of different materials can be
integrated into a single membrane structure (e.g., in layers, or
zones in the x-y plane of a membrane structure), or can be disposed
in series or in parallel as separate membrane structures or
modules. However, while any of the aforementioned polymers can
selectively permeate water vapor over oxygen and nitrogen,
maximizing the membrane's selectivity towards water will minimize
the loss of feed air through the membrane during operation when
vacuum is the driving force; hence, proper identification of a
membrane layer is an important consideration in the case of the
membrane dryer connected to a vacuum pump. Additional examples of
polymer membranes include polyimides, polycarbonates and
polysulfones.
Turning to FIG. 5 (which uses some same numbering from FIG. 3 to
identify like items in FIG. 5), an example embodiment of an
inerting system 150 with a solid oxide electrochemical cell stack
152 is shown. The system 150 includes a cathode heat recovery heat
exchanger 128 with sides 130 and 132, anode heat recovery heat
exchanger 134 with sides 136 and 138, flow control valves 142 and
143, solid oxide electrochemical cell stack 152, burner 144, and
inlet 154. The system 150 is arranged so cathode supply feed 22
from the protected space 54 flows into inlet 154 from blower 60,
through filter 64, through cathode heat recovery heat exchanger
128, to solid electrochemical stack 152, along the cathode fluid
flow path 23 where oxygen is removed, and then oxygen-depleted air
is routed through the hot side 132 of the cathode heat recovery
heat exchanger 128 and to condenser 66 before being sent back to
the protected space(s) or other fire suppression location. Anode
feed air can be used for temperature control, and is directed from
an outside air source (not shown) connected to inlet 140, through
anode heat recovery heat exchanger 134, through heater 146 to the
electrochemical cell stack 152 where it is delivered to the anode
side fluid flow path 25. Anode exhaust stream 26 is directed to
optional burner 144 and then to the hot side of heat exchanger 134
before being sent elsewhere.
The heat exchangers 128, 134, the flow control valve 142, heaters
146, 146', and burner 144 can control incoming process gas to a
range of 500-1000.degree. C., or a range of 650-850.degree. C.
Cathode supply feed from the inlet 154 first enters cathode heat
recovery heat exchanger 128. Cathode heat recovery heat exchanger
128 has two sides: cold side 130 and hot side 132. The cathode
supply feed enters cathode heat recovery heat exchanger 128 in cold
side 130, where process air is heated from the hot inert product
gas. Heated cathode supply feed is then routed to electrochemical
stack 152. Anode feed air can be used for simultaneous stack
cooling and dilution of oxygen on the anode side of electrochemical
stack 152. Anode air enters inlet 140 and is directed to anode heat
recovery heat exchanger 134 which has two sides: cold side 136 and
hot side 138. As shown in FIG. 5, the anode feed air is heated in
the anode heat recovery heat exchanger 134 cold side 136, and is
optionally further temperature-conditioned in heater 146' before
flowing to solid oxide electrochemical stack 152. Burner 144 is
optional, and can be used for oxygen-enriched combustion to
generate heat (for example during start-up). The combustion process
of a burner, if used depletes the gas stream of oxygen, and with
proper control of stoichiometry can generate additional inert
gas.
The flow of heated process air into the stack 152 can be regulated
by flow control valves 142, 143, allowing for both temperature and
safety control of the stack 152. Flow control valve 143 controls
flow of process air into the cathode side of the stack 152. Flow
control valve 142 can optionally regulate and shut off flow of
heated gas to the anode side of the stack 152. For example, if flow
control valve 142 is open and heated process gas is flowed into the
anode side of the stack 152, the heated air can warm up the stack
and allow quicker startup by promoting the kinetics of those
reactions. Less activation energy is required for the reactions
when the stack is at higher temperatures. At low oxygen removal
rates, additional heated air may be required to maintain a
desirable operating temperature.
When the solid oxide stack 152 is operating, cooling of anode
process air may be necessary to remove heat from internal
resistance losses resulting from irreversible processes.
Optionally, the system 150 can include a temperature sensor
proximate to the stack 152 in communication with the controller so
that the flow of cooling air or heated air through the stack 152
can be controlled based on current temperatures. Additionally, when
the solid oxide electrochemical stack 152 is running, the anode
evolves oxygen as described above in reference to FIG. 2. Flowing
dilution air into the anode side of the stack through valve 142 can
dilute oxygen exiting the anode, tailoring the concentration of
oxygen in OEA and preventing highly concentrated oxygen from
flowing through the aircraft, as hot oxygen is reactive and
potentially dangerous. Adjusting dilution air running into the
anode allows for specific gas composition (and oxygen
concentration) exiting the anode. Similarly, if a high
concentration exiting the anode side of stack 152 is desired for
further use as an oxidant for combustion, then less dilution air
can be used as long sufficient anode feed air flows to cool
electrochemical stack 152.
In addition to supplying ODA to the ullage of the fuel tank(s)
onboard the aircraft, the ODA may be also be used for other
functions, such as serving as a fire-suppression agent. For
example, cargo compartments onboard aircraft typically have
fire-suppression systems that include a dedicated gas-distribution
system comprising tubes routed to nozzles in the cargo bay to
deploy fire-suppression agents in the event of a fire. A variety of
fire-suppression agents may be deployed depending on the type and
extent of the fire. In the case of a fire, all or some of the ODA
could be routed to one or more of these fire-suppression
distribution systems. This may be especially beneficial during the
aircraft descent during a hull breach when the cargo bay is
becoming re-pressurized to reduce the ingress of oxygen that can
feed the fire. In this case, the system may be operated to produce
ODA at the maximum flow rate. The ODA could also be used to enable
inerting coverage over extended periods, which may be in addition
to, or in lieu of, dedicated low-rate discharge inerting systems in
the cargo bay(s).
During operation, the system can be controlled by controller 36 to
set fluid flow rates (e.g. feed rates of air to the cathode 14 or
to the anode 16, or of water or water vapor in the air feed to the
cathode 14 or CO.sub.2 in the air feed to cathode 14 or anode 16,
and the current or voltage levels produced by electric power source
20 to produce varying amounts of ODA in response to system
parameters. Such system parameters can include, but are not limited
to mission phase, temperature of the fuel in protected space(s) 56,
oxygen content of the fuel in the case of a fuel tank protected
space, oxygen content of gas in the protected space(s) 56, and
temperature and/or pressure of vapor in the ullage of any fuel tank
protected space(s), temperature and pressures in the
electrochemical cell stack 52/152, and temperature, oxygen content,
and/or humidity level of the inert gas. Accordingly, in some
embodiments, the fuel tank ullage gas management system such as
shown in FIGS. 3-5 can include sensors for measuring any of the
above-mentioned fluid flow rates, temperatures, oxygen levels,
humidity levels, or current or voltage levels, as well as
controllable output fans or blowers, or controllable fluid flow
control valves or gates. These sensors and controllable devices can
be operatively connected to a system controller. In some
embodiments, the system controller can be dedicated to controlling
the fuel tank ullage gas management system, such that it interacts
with other onboard system controllers or with a master controller.
In some embodiments, data provided by and control of the fuel tank
ullage gas management system can come directly from a master
controller.
In some embodiments, the inerting system can be operated
continuously to produce a gas in a fuel tank protected space that
is highly oxygen-depleted, which can promote a reduced load on the
system during descent when outside oxygen-containing air enters the
fuel tank. In some embodiments, the system can be turned off or
maintained in a stand-by mode during periods of low fire risk as
disclosed by U.S. patent application Ser. No. 15/378,687 filed Dec.
14, 2016, the disclosure of which is incorporated herein by
reference in its entirety.
As mentioned above, in some embodiments, the system can be operated
in an alternate mode as a fuel cell in which fuel (e.g., hydrogen)
is delivered to the anode and air is delivered to the cathode.
Depending on the fuel cell type, the fuel may be hydrogen, carbon
monoxide, natural gas (primarily methane), or any other suitable
reductant. At the anode, the fuel undergoes oxidation in which
electrons are liberated whereas at the cathode, the reduction of
oxygen ensues. Electricity produced by the electrochemical cell in
a power production mode is delivered to a power sink such a
power-consuming component or an electrical bus connected to one or
more power-consuming components. In some embodiments, the system
can be operated in a mode selected from a plurality of modes that
include at least the above-described power-consuming mode and
power-producing (fuel cell) mode (both of which produce ODA at the
cathode), and can also optionally include other modes such as a
start-up mode. In such embodiments, the electrical connection 18
(FIG. 2) would provide controllable connection to either a power
source or a power sink.
In some embodiments, various technical effects can be provided,
including but not limited to low oxygen concentrations in fuel tank
ullage spaces, reduced power consumption compared to
electrochemical cell-based inerting systems that use fresh air for
the cathode supply feed, capability to operate when fuel tanks are
low on fuel vapor such as at cruise conditions (compared to a
catalytic combustion reactor that requires fuel vapor to produce
ODA), and no generation of CO.sub.2 or water (compared to catalytic
combustion reactors that produce CO.sub.2 and water, which can
require additional handling measures).
The term "about", if used, is intended to include the degree of
error associated with measurement of the particular quantity based
upon the equipment available at the time of filing the application.
For example, "about" can include a range of .+-.8% or 5%, or 2% of
a given value.
The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the present disclosure. As used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, integers, steps, operations, elements, and/or components,
but do not preclude the presence or addition of one or more other
features, integers, steps, operations, element components, and/or
groups thereof.
While the present disclosure has been described with reference to
an exemplary embodiment or embodiments, it will be understood by
those skilled in the art that various changes may be made and
equivalents may be substituted for elements thereof without
departing from the scope of the present disclosure. In addition,
many modifications may be made to adapt a particular situation or
material to the teachings of the present disclosure without
departing from the essential scope thereof. Therefore, it is
intended that the present disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this present disclosure, but that the present
disclosure will include all embodiments falling within the scope of
the claims.
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